Foreword

The Operator's Manual

You and others can be killed or seriously injured

if you operate or maintain the machine without
first studying the Operator's Manual. You must
understand and follow the instructions in the
Operator's Manual. If you do not understand
anything, ask your employer or JCB dealer to
explain it.

SERVICE MANUAL Do not operate the machine without an Operator's

Manual, or if there is anything on the machine you
do not understand.

Treat the Operator's Manual as part of the machine.

Keep it clean and in good condition. Replace the
Operator's Manual immediately if it is lost, damaged
or becomes unreadable.

LOADER
455ZX Contents
01 - Machine
03 - Attachments, Couplings and Load
Handling
06 - Body and Framework
09 - Operator Station
12 - Heating, Ventilating and Air-
Conditioning (HVAC)
15 - Engine
18 - Fuel and Exhaust System
21 - Cooling System
24 - Brake System
EN - 9813/4800 - ISSUE 3 - 11/2017
25 - Steering System
27 - Driveline
30 - Hydraulic System
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
33 - Electrical System
72 - Fasteners and Fixings
75 - Consumable Products

Copyright 2017 © JCB SERVICE

78 - After Sales
All rights reserved. No part of this publication may
be reproduced, stored in a retrieval system, or
transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise,
without prior permission from JCB SERVICE.

www.jcb.com
 15 - Engine
12 - Crankshaft
00 - General

Component Identification
Figure 152.

B
A Crankshaft
B Crankcase

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 15 - Engine
12 - Crankshaft
00 - General

Operation

Refer to Camshaft - Introduction. Refer to: PIL the diameter of the upper main bearing shell allows
15-15-00. oil transfer to cross drillings in the crankshaft to feed
each of the big end bearings. Crankshaft gear is
Lubrication 'splash' lubricated. Front and rear crankshaft oil seals
prevent oil leakage from, and dirt ingress to, the
Oil is fed from the main gallery via seven drillings, engine.
one to each of the main bearings. A groove around

Figure 153.

2 2 2 2
2 5 2 2
5
5
5
4 4
3 3
4 4
3
3 3 3
3
4 4
5 5

2
7
2
2
6 2
2
4 2
2
3
3
3
4 3
3 4
4
4 3
4
3

1 Main gallery 2 Drillings (x7)

3 Main bearings 4 Big end bearings
5 Cross drillings 6 Crankshaft gear
7 Crankshaft oil seal

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 15 - Engine
12 - Crankshaft
00 - General

Check (Condition) Figure 156.

1. Check the main bearing surfaces for damage and

excessive wear.
C
Figure 154. D
A

C J-jets
D Fixing screws

A Main bearing shells

2. Measure the crankshaft diameters to confirm
they are within service limits, refer to Technical
Data (PIL 15-12).
Figure 155.

B Crankshaft
3. Check that the oil-way cross drillings in the
crankshaft are clear and free from debris.
Blocked or restricted oil-ways will cause oil
starvation at the big end bearings.
4. Check that the piston cooling J-jets are clear. If
the J-jets cannot be cleared remove the fixing
screws. Remove the J-jets and discard them.
5. Install new J-jets.

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 15 - Engine
12 - Crankshaft
00 - General

Remove and Install 18. Remove the fuel injection pump drive gear, refer
to (PIL 15-51).
Consumables
Description Part No. Size 19. Remove the oil pump, refer to (PIL 15-60).
Cleaner/Degreaser 4104/1557 0.4L 20. Remove the high duty PTO idler drive gear (if
- General purpose installed), refer to (PIL 15-51).
solvent based parts
cleaner 21. Remove the crankshaft drive gear, refer to (PIL
15-51).
CAUTION This component is heavy. It must only
be removed or handled using a suitable lifting 22. Remove the camshaft, refer to (PIL 15-15).
method and device.
23. Remove the rear timing case, refer to (PIL
15-51).
Before Removal 24. If the pistons and connecting rods have not been
1. This procedure requires service parts. Make removed, undo and remove the main bearing
sure you have obtained the correct service parts caps, refer to (PIL 15-12).
before you start, refer to Parts Catalogue.
25. Remove the bedplate, refer to (PIL 15-09).
2. Make sure that the engine is safe to work on. If
the engine has been running, let it cool before Remove
you start the service work.
1. Remove the thrust washers between the
3. Remove the engine, refer to (PIL 15-00). crankshaft and crankcase rear main bearing.
4. Remove the drive belt, refer to (PIL 15-18). Figure 157.
A
5. Remove the crankshaft pulley, refer to (PIL
15-12).
6. Remove the oil sump, refer to (PIL 15-45).
B
7. Disconnect and remove the fuel pipes from the
injectors, refer to (PIL 18-96). A
8. Remove the rocker cover, refer to (PIL 15-42).
C
9. Remove the fuel injectors, refer to (PIL 18-18).
10. Remove the rocker assembly including the push
rods, refer to (PIL 15-42).
11. It is not necessary to remove the cylinder head A Thrust Washers
assembly to remove the crankshaft. If however B Crankshaft
the cylinder head needs to be removed for other C Rear main bearing
reasons (for piston and connecting rod removal
for example) remove it now, refer to (PIL 15-06). 2. Put labels on the thrust washers to make sure
that they are installed in the correct positions
12. Remove the fuel injection pump, refer to (PIL during assembly.
18-18).
3. Use suitable lifting equipment to carefully lift the
13. Remove the starter motor, refer to (PIL 15-75). crankshaft from the crankcase (if the crankshaft
is lifted manually, two people will be required).
14. Remove the high duty PTO device (if installed).
4. Carefully lift out the bearing shells.
15. Position the engine upside down in a suitable jig
or fixture, supported at the front of the cylinder
block.
16. Remove the flywheel, refer to (PIL 15-54).
17. Remove the flywheel housing, refer to (PIL
15-54).

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 15 - Engine
12 - Crankshaft
00 - General

Figure 158. Figure 159.

A

C
D

A Main bearing shells

C J jets (x4)
5. It is recommended that the bearing shells are D Fixing screws
replaced. If however they are to be used again,
put label on the shells to make sure that they 3.1. Insert the cooling jets into the crankcase.
are installed in their original positions during
assembly. 3.2. Note: There are different types of cooling
jets installed depending on the engine
6. Inspect the crankshaft and main bearings etc. application. The jets are colour coded.
for damage and excessive wear. Refer to Check 3.3. Be sure to install the correct jets. Refer to
Condition (PIL 15-12). the relevant parts catalogue for the correct
cooling jet identification.
Before Installation
3.4. Tighten the retaining screws to the correct
1. Clean off all traces of the old sealant compound torque value.
from the crankcase and bedplate mating faces.
4. Install the upper bearing shells as follows:
2. Use a suitable degreasing agent to carefully
clean the main bearing saddles in the bedplate 4.1. Use a suitable degreasing agent to make
and crankcase. Take care not to block the oil sure that the surface of the upper bearing
ways or the piston cooling jets. shells are clean.
Consumable: Cleaner/Degreaser - General Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner purpose solvent based parts cleaner
4.2. Assemble the bearing shells into the
Important: Cleanliness is of the utmost importance. crankcase bearing saddles. Make sure that
Blocked oil-ways or oil jets will cause engine failure. the location tab engages into the slot as
Before you install the crankshaft make sure that ALL shown.
oil-ways and jets are clear and free from debris.
4.3. Important: Make sure that the oil-way holes
Install in the bearing saddles align with the holes
in the bearing shell. If the holes are even
1. The installation procedure is the opposite of the partially misaligned the piston cooling oil jet
removal procedure. Additionally do the following will be restricted, causing the engine to fail.
steps. 4.4. Lubricate the upper bearing shells with
clean engine oil.
2. Make sure that all items are clean and free from
damage and corrosion. 5. Use suitable lifting equipment (if the crankshaft
is lifted manually, two people will be required), to
3. If removed or a new crankcase is being installed
carefully lower the crankshaft into the crankcase.
then install cooling J jets as follows:
DO NOT rotate the crankshaft, the bearing shells
can become dislodged, refer to step 4.
6. Install the thrust washers as follows:

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 15 - Engine
12 - Crankshaft
00 - General

Figure 160.
A A

H
B

A Thrust washers
B Crankshaft
C Rear main bearing
H Oil slot - thrust washers
6.1. Slide the thrust washers between the
crankshaft and the crankcase rear main
bearing.
6.2. Make sure that they are installed in the
correct positions, with the two slots facing
outwards from the bearing saddle.
6.3. If necessary, push the crankshaft forward
and then backwards to obtain clearance to
install the thrust washers.
6.4. DO NOT rotate the crankshaft, the bearing
shells can become dislodged, refer to step
4.
7. Check that the crankshaft end float is within
service limits, refer to Technical Data (PIL 15-12).

Table 62. Torque Values

Item Nm
F 24

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 15 - Engine
12 - Crankshaft
03 - Main Bearing

03 - Main Bearing Introduction

Introduction .................................................... 15-67 In a piston engine, the main bearings are the
Check (Condition) .......................................... 15-68 bearings on which the crankshaft rotates.
Remove and Install ....................................... 15-68
The bearings hold the crankshaft in place and
prevent the forces created by the piston and
transmitted to the crankshaft by the connecting rods
from dislodging the crankshaft, instead forcing the
crank to convert the reciprocating movement into
rotation.

Figure 161.

A Main bearing
B Crankshaft

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 15 - Engine
12 - Crankshaft
03 - Main Bearing

Check (Condition) Remove and Install

Refer to: PIL 15-12-00.
1. Check the bearing shell surfaces for signs of
damage and excessive wear.
2. Measure the crank pin diameters to confirm they
are within service limits.
Refer to: PIL 15-12-00.
3. Renew any parts that are worn or not within the
specified tolerances.

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 15 - Engine
12 - Crankshaft
06 - Front Oil Seal

06 - Front Oil Seal

Remove and Install

Special Tools Figure 162.

Description Part No. Qty.
Crankshaft Front Oil 892/01157 1 C
Seal Installation Tool
B
Before Removal
1. This procedure requires service parts. Make
sure you have obtained the correct service parts
before you start, refer to Parts Catalogue.
2. Make sure that the engine is safe to work on. If
the engine has been running, let it cool before
you start the service work.
3. Get access to the engine. A

4. Remove the drive belt, refer to (PIL 15-18).

5. Remove the crankshaft pulley, refer to (PIL
15-12-12).
A Crankshaft oil seal
Remove B Crankcase
C Crankshaft hub
1. Use a suitable lever behind the lip of the
seal, carefully prise out the oil seal from the
counterbore in the crankcase. Take care not Install
to scratch or damage the counterbore or the 1. Make sure that the counterbore and the
crankshaft hub. Damaged or dirty sealing faces crankshaft hub are clean and free from damage
will cause the oil seal to fail. and corrosion. Use a suitable degreasing agent
to clean all traces of oil and grease from the
counterbore. Important: The oil seal has a special
coating and MUST be installed dry without
lubricant.
2. Dismantle the seal installation tool. Bolt the
centre body to the crankshaft hub, using the
bolts. Refer to Figure 163.
Special Tool: Crankshaft Front Oil Seal
Installation Tool (Qty.: 1)
3. Install the oil seal on to the centre body. Make
sure that the seal is installed the correct way
around. Assemble the outer sleeve on to the
centre body and install the screw. Refer to Figure
163.

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 15 - Engine
12 - Crankshaft
06 - Front Oil Seal

Figure 163.

F D A

G G
E

A Crankshaft oil seal B Crankcase

C Crankshaft hub D Seal installation tool
E Fixing bolts (x3) F Centre body
G Outer sleeve H Screw

4. Turn the screw to push the seal squarely into Figure 164.
the counterbore until the outer sleeve comes
up against the front edge of the counterbore. B
When correctly installed, the front face of the seal
should be flush with the edge of the counterbore A
within the specified tolerance. Refer to Figure
164. G

Dimension: -0.5 -0/+0.5mm

C
A Crankshaft oil seal
B Crankcase
C Crankshaft hub
F Centre body
G Outer sleeve
5. Remove the seal installation tool.

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 15 - Engine
12 - Crankshaft
06 - Front Oil Seal

After Installation
1. Install the crankshaft pulley, refer to (PIL
15-12-12).
2. Install the drive belt, refer to (PIL 15-18).

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 15 - Engine
12 - Crankshaft
09 - Rear Oil Seal

09 - Rear Oil Seal

Remove and Install

Special Tools Figure 166. 15mm Hub

Description Part No. Qty.
Crankshaft Rear Oil 892/01156 1
Seal Installation Tool A
Crankshaft Rear Oil 892/01158 1
Seal Alignment Tool
B
Note: The flywheel hub and crankshaft rear oil seal
need to be replaced as a pair.

Before Removal
1. This procedure requires service parts. Make
sure you have obtained the correct service parts
before you start, refer to Parts Catalogue.
2. Make sure that the engine is safe to work on. If
the engine has been running, let it cool before
you start the service work. C E

3. Get access to the engine. A Crankshaft rear oil seal

B Flywheel housing
4. Remove the flywheel, refer to (PIL 15-54). C Flywheel hub
E Fixing bolt
Remove
Install (24mm Hub)
1. Use a suitable lever behind the lip of the seal
to carefully prise out the rear oil seal from the 1. Make sure that the counterbore and the flywheel
counterbore in the flywheel housing. Take care hub are clean and free from damage and
not to scratch or damage the counterbore or the corrosion.
flywheel hub. Damaged or dirty sealing faces will
cause the oil seal to fail.
Figure 165. 24mm Hub

C B
A Crankshaft rear oil seal
B Flywheel housing
C Flywheel hub

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 15 - Engine
12 - Crankshaft
09 - Rear Oil Seal

Figure 167.

B
D
A
C

A Crankshaft rear oil seal B Flywheel housing

C Flywheel hub D Oil seal alignment tool

2. To prevent the seal lip rolling over and becoming Special Tool: Crankshaft Rear Oil Seal Alignment
damaged, make sure that you use the oil seal Tool (Qty.: 1)
alignment tool to initially install the oil seal on to
the flywheel hub. Locate the alignment tool over 3. Apply lubricant P80 around the seal outer rubber
the end of the hub, then carefully push the oil seal diameter.
over the alignment tool and on to the crankshaft
diameter. Make sure that the oil seal is installed 4. Dismantle the oil seal installation tool. Bolt the
the correct way around. centre body to the flywheel hub, using the two
flywheel bolts. Assemble the outer sleeve on to
Special Tool: Crankshaft Rear Oil Seal the centre body and install the screw.
Installation Tool (Qty.: 1)

Figure 168.
F
B
E
A C H

H
G

G F

A Crankshaft rear oil seal B Flywheel housing

C Outer sleeve E Oil seal installation tool
F Flywheel bolts G Centre body
H Flywheel hub J Screw

5. Turn the screw to push the seal squarely into 6. Remove the oil seal installation tool.
the counterbore until the outer sleeve comes
up against the front edge of the counterbore. Install (15mm Hub)
When correctly installed, the front face of the seal
should be flush with the edge of the counterbore 1. Make sure that the counterbore and the hub are
within the tolerance specified. clean and free from damage.
Length/Dimension/Distance: 0.5mm

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 15 - Engine
12 - Crankshaft
09 - Rear Oil Seal

Figure 169.

B
D
A
C

A Crankshaft rear oil seal B Flywheel housing

C Flywheel hub D Oil seal alignment tool

2. Install the new hub on to the crankshaft gear and Special Tool: Crankshaft Rear Oil Seal
install the old hub on the outside of the new hub Installation Tool (Qty.: 1)
to create a double thickness flywheel hub, install Special Tool: Crankshaft Rear Oil Seal Alignment
the fixing bolt as shown at A. Do not touch the Tool (Qty.: 1)
PTFE seal lips of the crankshaft oil seal.
4. Apply the lubricant P80 around the seal outer
3. Make sure that you use the oil seal alignment tool rubber diameter.
to initially install the oil seal on to the flywheel
hub to prevent damage to the seal lip. Locate the 5. Dismantle the oil seal installation tool. Use the
alignment tool over the end of the hub, carefully two flywheel bolts to attach the centre body on to
push the oil seal over the alignment tool as far the flywheel hub. Assemble the outer sleeve on
on to the crankshaft hub as possible. Make sure to the centre body include the extension ring and
that the seal is installed the correct way around. install the screw.

Figure 170.
B F
G
A C1 K C2
H
L

K
J

A Crankshaft rear oil seal B Flywheel housing

C1 New hub C2 Old hub
F Flywheel bolts G Oil seal installation tool
H Extension ring J Centre body
K Outer sleeve L Screw

6. Turn the screw to push the seal into position in

the counterbore so that the screw will not turn.

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 15 - Engine
12 - Crankshaft
09 - Rear Oil Seal

7. Remove the oil seal installation tool, remove the

old hub and install the fixing bolt. Repeat steps 5
and 6 to fully install the rear oil seal.
8. Remove the oil seal installation tool.

After Installation
1. Install the flywheel, refer to (PIL 15-54).

Table 63. Torque Values

Item Nm
E 47

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 15 - Engine
12 - Crankshaft
12 - Pulley

12 - Pulley Install
1. The installation procedure is the opposite of the
Remove and Install removal procedure. Additionally do the following
steps.
Special Tools
Description Part No. Qty. 2. Make sure that all items are clean and free from
Torque Wrench 993/70111 1 damage and corrosion.
(10-100Nm)
3. Renew the fixing bolts. Tighten the new bolts in
three stages to the correct torque value.
Before Removal
Special Tool: Torque Wrench (10-100Nm) (Qty.:
1. This procedure requires service parts. Make 1)
sure you have obtained the correct service parts
before you start, refer to Parts Catalogue. 4. The bolts are tightened using a torque and
angle method. Refer to Fasteners and Fixings,
2. Make sure that the engine is safe to work on. If General, Introduction (PIL 72-00).
the engine has been running, let it cool before
you start the service work. Figure 172.

3. Get access to the engine.

4. Remove the drive belt. Refer to (PIL 15-18).

Remove
1. Remove the fixing bolts and withdraw the pulley C
from the crankshaft.
Figure 171.

C Angle gauge (obtain locally)

After Replacement
1. Install the drive belt. Refer to (PIL 15-18).
A
Table 64.
Item Torque Value Torque Angle
(Nm) (Degrees)
2 (1st stage) 30N·m
2 (2nd stage) 75N·m
2 (Final stage) 180°

A
B
A Crankshaft pulley
B Fixing bolts (x3)
2. The bolts must not be reused. Discard the bolts.

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 15 - Engine
15 - Camshaft
00 - General

Remove and Install

Before Removal 6. Remove the starter motor. Refer to (PIL

15-75-00).
1. Drain the oil from the engine. Refer to (PIL
15-21-00). 7. Remove the oil sump. Refer to (PIL 15-45-00).

2. Disconnect and remove the fuel pipes from the 8. Remove the flywheel. Refer to (PIL 15-54-00).
injectors. Refer to (PIL 18-96-03).
9. Remove the flywheel housing. Refer to (PIL
3. Remove the rocker cover. Refer to (PIL 15-54-03).
15-42-06).
10. Rotate the crankshaft until the camshaft timing
4. Remove the fuel injection pump. pin can be inserted through the gear and into the
aligning hole in the rear gear case.
5. Remove the rocker assembly and push rods.

Figure 175.

A Timing pin - camshaft

11. Remove the taper blanking plug and insert

the crankshaft locking pin. The camshaft and
crankshaft locking pins must be in position to lock
the crankshaft and camshaft before removing the
camshaft assembly.

15 - 85 9813/4800-3 15 - 85
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 15 - Engine
15 - Camshaft
00 - General

Figure 176. 12. Remove the fuel injection pump drive gear. Refer
to (PIL 15-51-09).

Remove
The engine must be inverted. DO NOT attempt
to remove the camshaft and its drive gears with
the engine upright. The tappets and push rods will
fall into the engine and further dismantling will be
required to retrieve them.

1. Remove the camshaft timing pin.

2. Carefully withdraw the camshaft and gear
assembly from the crankcase. Make sure you
fully support the camshaft to prevent the lobes
B contacting the bearing surfaces in the crankcase.
The bearing surfaces can easily be damaged by
C the sharp hard edges on the cam lobes.

B Timing pin - crankshaft

C Blanking plug

Figure 177.

A Timing pin - camshaft D Camshaft and drive gear

3. Access the tappets through the apertures in

the crankcase bedplate next to the crankshaft.
Lift out the tappets from the crankcase using a
suitable magnetic probe. Label the tappets for
replacement in their original positions.

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 15 - Engine
15 - Camshaft
00 - General

Figure 178. 2. Note that the fuel injection pump drive gear
fixing nut is torque tightened as part of the fuel
F injection pump replacement procedure. Refer to
(PIL 18-18-15).

E Tappet (8 off)
F Magnetic probe

Inspection
1. Refer to Camshaft- Check Condition (PIL 15-15).

Install
1. Lubricate the tappets and tappet bores inside the
crankcase with clean engine oil.
2. Insert the tappets in their original positions in the
crankcase using a suitable magnetic probe.
3. Lubricate the camshaft bearing journals inside
the crankcase with clean engine oil.
4. Carefully insert the camshaft assembly into the
crankcase as shown. Support the camshaft
preventing the lobes contacting the bearing
surfaces in the crankcase. Before meshing the
camshaft gear with the crankshaft gear, rotate
the camshaft until the timing hole in the gear
aligns with the dowel hole in the gear case. Insert
the timing pin T1 to lock the camshaft in this
position.

After Installation
1. The after installation procedure is the opposite
of the before removal procedure. Additionally do
the following step.

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